U.S. patent application number 14/835441 was filed with the patent office on 2015-12-17 for segmented smoking article with substrate cavity.
This patent application is currently assigned to R.J. REYNOLDS TOBACCO COMPANY. The applicant listed for this patent is R.J. REYNOLDS TOBACCO COMPANY. Invention is credited to Chandra K. Banerjee, Vernon Brent Barnes, Carolyn R. Carpenter, Yi-Ping Chang, Billy Tyrone Conner, Evon Llewellyn Crooks, Alvaro Gonzalez-Parra, David Neil McClanahan, Timothy B. Nestor, Andries Don Sebastian, James Richard Stone, Timothy Frederick Thomas, Jackie L. White.
Application Number | 20150359259 14/835441 |
Document ID | / |
Family ID | 45816601 |
Filed Date | 2015-12-17 |
United States Patent
Application |
20150359259 |
Kind Code |
A1 |
Conner; Billy Tyrone ; et
al. |
December 17, 2015 |
SEGMENTED SMOKING ARTICLE WITH SUBSTRATE CAVITY
Abstract
A cigarette includes lighting and mouth ends. It may include a
smokable segment disposed at the lighting end. It also includes a
mouth-end segment; an aerosol-generation system disposed between
the lighting and mouth ends, which includes (i) a heat-generation
segment adjacent the smokable segment, including a heat source and
an insulation layer and (ii) an aerosol-generating segment
including a substrate, which may include tobacco pellets and
aerosol-forming material disposed in a substrate cavity between the
heat generation segment and the mouth end; a piece of outer
wrapping material that provides an overwrap around at least a
portion of the aerosol-generating segment, the heat-generation
segment, and at least a portion of the smokable segment and
includes a foil strip laminated thereon; those segments being
connected together by the overwrap to provide a cigarette rod; that
is connected to the mouth-end segment using tipping material.
Inventors: |
Conner; Billy Tyrone;
(Clemmons, NC) ; Sebastian; Andries Don;
(Clemmons, NC) ; Crooks; Evon Llewellyn;
(Mocksville, NC) ; Thomas; Timothy Frederick;
(High-Point, NC) ; Stone; James Richard; (Advance,
NC) ; Banerjee; Chandra K.; (Clemmons, NC) ;
Chang; Yi-Ping; (Greensboro, NC) ; Barnes; Vernon
Brent; (Advance, NC) ; Gonzalez-Parra; Alvaro;
(Clemmons, NC) ; McClanahan; David Neil;
(Winston-Salem, NC) ; Carpenter; Carolyn R.;
(Lewisville, NC) ; Nestor; Timothy B.; (Advance,
NC) ; White; Jackie L.; (Pfafftown, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
R.J. REYNOLDS TOBACCO COMPANY |
Winston-Salem |
NC |
US |
|
|
Assignee: |
R.J. REYNOLDS TOBACCO
COMPANY
Winston-Salem
NC
|
Family ID: |
45816601 |
Appl. No.: |
14/835441 |
Filed: |
August 25, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13236962 |
Sep 20, 2011 |
9149072 |
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14835441 |
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12775130 |
May 6, 2010 |
8839799 |
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13236962 |
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12775278 |
May 6, 2010 |
8424538 |
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12775130 |
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12859494 |
Aug 19, 2010 |
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12775278 |
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Current U.S.
Class: |
131/280 ;
131/194 |
Current CPC
Class: |
A24F 47/006 20130101;
A24B 15/165 20130101; A24C 5/00 20130101; A24D 1/08 20130101 |
International
Class: |
A24D 1/08 20060101
A24D001/08; A24C 5/00 20060101 A24C005/00 |
Claims
1. A cigarette comprising: a lighting end and a mouth end with a
mouth end segment disposed at the mouth end; a tobacco rod disposed
between the lighting end and the mouth end segment; an
aerosol-generation system disposed between the lighting end and the
tobacco rod, the aerosol-generation system including a heat
generation segment disposed at the lighting end, with a heat source
configured to be activated by ignition of the lighting end and an
insulation layer of flame-retardant material around a portion of
the heat source; and an aerosol-generating segment including a
tobacco pellet substrate that is disposed within a first substrate
cavity defined between the heat generation segment and the tobacco
rod, where the tobacco pellet substrate contacts the heat
generation segment at one end of the substrate cavity and contacts
the tobacco rod at the other end of the substrate cavity; a
wrapping material formed as a paper material tube circumscribes the
aerosol-generating segment; wherein the wrapping material comprises
a foil strip laminated to a surface of the paper material tube,
which foil strip circumferentially encompasses and extends
lengthwise along at least a lengthwise portion of the substrate
cavity.
2. The cigarette of claim 1, where the surface of the paper
material tube to which the foil strip is laminated is an
inward-facing surface of the paper material tube.
3. The cigarette of claim 1, wherein the foil strip extends along
substantially an entire length of the substrate cavity.
4. The cigarette of claim 1, wherein the wrapping material contacts
the heat generation segment and the tobacco rod.
5. A method for making a cigarette according to claim 1, said
method comprising steps of: providing the paper material tube
including the foil strip; positioning the heat generation segment
adjacent a first end of the tube; delivering the tobacco pellet
substrate into the tube adjacent to the heat generation segment and
within first substrate cavity; and delivering the tobacco rod
adjacent to the tobacco pellet substrate at an end of the tobacco
pellet substrate that is opposite from the heat generation
segment.
6. The method of claim 5, where the paper material tube is
vertically oriented during at least the step of delivering the
tobacco pellet substrate.
7. The method of claim 5, adapted to form a two-up rod for assembly
of the cigarette, said method further comprising steps of:
providing the paper material tube, constructed with a greater
length than for a one-up rod; delivering the second tobacco pellet
substrate into the tube within the substrate cavity; and
positioning a second heat generation segment adjacent a second end
the tube, longitudinally opposite the first end of the tube.
8. The method of claim 7, where the tube is vertically oriented
during at least the step of introducing a second tobacco pellet
substrate.
9. The method of claim 7, further comprising severing the two-up
rod into two intermediate segments.
10. The method of claim 9, further comprising steps of assembling a
tobacco rod and a mouth-end segment to the tube of each of the two
intermediate segments.
11. The method of claim 5, wherein the step of providing the paper
material tube further comprises a step of forming the tube from a
paper sheet.
12. The method of claim 11, wherein the foil strip is laminated to
the paper sheet before the step of forming the tube.
13. The method of claim 11, where the paper sheet is sized and
shaped to circumscribe the at least a portion of the heat
generation segment, the aerosol-generating segment, and the at
least a portion of the tobacco rod.
14. The method of claim 13, where the paper sheet is substantially
rectangular in shape.
15. A cigarette comprising: a lighting end and a mouth end; an
aerosol-generation system disposed between the lighting end and the
mouth end, the aerosol-generation system including a heat
generation segment disposed at the lighting end, with a heat source
configured to be activated by ignition of the lighting end and an
insulation layer of flame-retardant material around a portion of
the heat source; and an aerosol-generating segment including a
tobacco pellet substrate that is disposed within a substrate cavity
defined at one end by the heat generation segment and at an
opposite end by a tobacco rod where the tobacco pellet substrate
contacts the heat generation segment and contacts the tobacco rod;
a paper wrapping material tube that circumscribes at least a
portion of the heat generation segment, the aerosol-generating
segment, and at least a portion of the tobacco rod; a foil strip
laminated to an interior surface of the paper wrapping material
tube, which foil strip circumferentially encompasses and extends
along at least a lengthwise portion of the substrate cavity and
overlaps a lengthwise portion of the heat generation segment;
wherein, a first lengthwise portion of the wrapping material
comprises unlaminated paper material not covered by the foil strip,
an intermediate second lengthwise portion of the wrapping material
extends from the first lengthwise portion wherein the foil strip
directly contacts and circumferentially encompasses the tobacco
pellet substrate, and a third lengthwise portion also comprises
unlaminated paper material not covered by the foil strip.
16. A cigarette comprising: a lighting end and a mouth end with a
mouth end segment disposed at the mouth end; a tobacco rod disposed
between the lighting end and the mouth end segment; an
aerosol-generation system disposed between the lighting end and the
tobacco rod, the aerosol-generation system including a heat
generation segment disposed at the lighting end, with a heat source
configured to be activated by ignition of the lighting end and an
insulation layer of flame-retardant material around a portion of
the heat source; and an aerosol-generating segment including a
paper material tube to which a foil material is laminated on an
inward-facing surface of the paper material tube that defines a
first substrate cavity so that the foil material circumferentially
encompasses and extends lengthwise along at least a lengthwise
portion of the substrate cavity; and a tobacco pellet substrate
disposed within the first substrate cavity, further defined at one
longitudinal end by the heat generation segment and at an opposite
longitudinal end by the tobacco rod, where the tobacco pellet
substrate contacts the heat generation segment and contacts the
tobacco rod.
17. The cigarette of claim 16, further comprising heat conductive
material extending from the heat source to around the
aerosol-generating segment.
18. The cigarette of claim 18, wherein the heat conductive material
provides a heat exchange relationship between the heat source and
the tobacco pellet substrate disposed within the aerosol-generating
segment.
19. The cigarette of claim 16, wherein the tobacco pellet substrate
comprises tobacco blend powder, glycerol, and calcium carbonate.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of, and claims priority
under 35 U.S.C. .sctn.120 to co-pending U.S. patent application
Ser. No. 13/236,962, filed Sep. 20, 2011, which is a
continuation-in-part of U.S. patent application Ser. No.
12/775,130, filed May 6, 2010; Ser. No. 12/775,278, filed May 6,
2010; and Ser. No. 12/859,494, filed Aug. 19, 2010, each of which
is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to products made or derived
from tobacco, or that otherwise incorporate tobacco, and are
intended for human consumption. The present application relates
particularly to components and configurations of segmented-type
smoking articles.
BACKGROUND
[0003] Popular smoking articles, such as cigarettes, have a
substantially cylindrical rod-shaped structure and include a
charge, roll or column of smokable material, such as shredded
tobacco (e.g., in cut filler form), surrounded by a paper wrapper,
thereby forming a so-called "smokable rod", "tobacco rod" or
"cigarette rod." Normally, a cigarette has a cylindrical filter
element aligned in an end-to-end relationship with the tobacco rod.
Preferably, a filter element comprises plasticized cellulose
acetate tow circumscribed by a paper material known as "plug wrap."
Preferably, the filter element is attached to one end of the
tobacco rod using a circumscribing wrapping material known as
"tipping paper." It also has become desirable to perforate the
tipping material and plug wrap, in order to provide dilution of
drawn mainstream smoke with ambient air. Descriptions of cigarettes
and the various components thereof are set forth in Tobacco
Production, Chemistry and Technology, Davis et al. (Eds.) (1999)
and U.S. Pat. No. 7,503,330 to Borschke et al, which is
incorporated herein by reference. A cigarette is employed by a
smoker by lighting one end thereof and burning the tobacco rod. The
smoker then receives mainstream smoke into his/her mouth by drawing
on the opposite end (e.g., the filter end) of the cigarette.
[0004] Certain types of cigarettes that employ carbonaceous fuel
elements have been commercially marketed under the brand names
"Premier" and "Eclipse" by R. J. Reynolds Tobacco Company. See, for
example, those types of cigarettes described in Chemical and
Biological Studies on New Cigarette Prototypes that Heat Instead of
Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988) and
Inhalation Toxicology, 12:5, p. 1-58 (2000). More recently, a
cigarette has been marketed in Japan by Japan Tobacco Inc. under
the brand name "Steam Hot One." It has also been suggested that the
carbonaceous fuel elements of segmented types of cigarettes may
incorporate ultrafine particles of metals and metal oxides. See,
for example, U.S. Pat. App. Pub. No. 2005/0274390 to Banerjee et
al., which is incorporated by reference herein in its entirety.
[0005] Yet other types of smoking articles, such as those types of
smoking articles that generate flavored vapors by subjecting
tobacco or processed tobaccos to heat produced from chemical or
electrical heat sources are described in U.S. Pat. No. 5,285,798 to
Banerjee et al. and U.S. Pat. No. 7,290,549 to Banerjee et al., and
U.S. Pat. App. Pub. No. 2008/0092912 to Robinson et al., which are
incorporated by reference herein in their entirety. One type of
smoking article that has employed electrical energy to produce heat
has been commercially marketed by Philip Morris Inc. under the
brand name "Accord."
[0006] Smoking articles that employ sources of heat other than
tobacco cut filler to produce tobacco-flavored vapors or
tobacco-flavored visible aerosols have not received widespread
commercial success. However, it would be highly desirable to
provide smoking articles that demonstrate the ability to provide to
a smoker many of the benefits and advantages of conventional
cigarette smoking, without delivering considerable quantities of
incomplete combustion and pyrolysis products.
SUMMARY
[0007] Embodiments of the present invention relate to smoking
articles, and in particular, to rod-shaped smoking articles, such
as cigarettes. A smoking article includes a lighting end (i.e., an
upstream end) and a mouth end (i.e., a downstream end). The smoking
article also includes an aerosol-generation system that includes
(i) a heat generation segment, and (ii) an aerosol-generating
region or segment located downstream from the heat generation
segment. The aerosol-generating segment may include a substrate
including pellets or beads of marumarized or non-marumarized
tobacco disposed within a substrate cavity. The substrate cavity
may be circumscribed by a foil strip laminated to a wrapping
material.
[0008] Further features and advantages of the present invention are
set forth in more detail in the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Embodiments may better be understood with reference to the
following drawings, which are illustrative only and are not
limiting.
[0010] FIGS. 1-2 provide longitudinal cross-sectional views of
representative smoking articles;
[0011] FIG. 3 shows a representative fuel element;
[0012] FIGS. 4-6 each show a longitudinal cross-sectional view of a
representative smoking article including a monolithic
substrate;
[0013] FIG. 7 shows a longitudinal cross-sectional view of a
representative smoking article including a tobacco pellet
substrate;
[0014] FIG. 8 shows a two-up rod that may be used for manufacturing
the smoking article of FIG. 7;
[0015] FIG. 9 shows a wrapping material that may be used for
manufacturing the two-up rod of FIG. 8.
[0016] FIG. 10 shows one example of the construction of a smoking
article;
[0017] FIG. 11 shows a representative smoking article including a
tobacco pellet substrate; and
[0018] FIG. 12 shows another example of the construction of a
smoking article.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Aspects and embodiments of the present invention relating to
various smoking articles, the arrangement of various components
thereof, and the manner that those smoking articles incorporate
overwrap components, are illustrated with reference to FIGS. 1 and
2. Like components are given like numeric designations throughout
the figures. For the various figures, the thicknesses of the
various wrapping materials and overwraps of the various smoking
articles and smoking article components are exaggerated. Most
preferably, wrapping materials and overwrap components are tightly
wrapped around the smoking articles and smoking article components
to provide a tight fit, and provide an aesthetically pleasing
appearance. Exemplary smoking article construction may include
features such as fibrous filter elements, foamed ceramic monoliths
formed as insulators or fuel elements, and other features disclosed
in U.S. Pat. App. Pub. No. 2011/0041861 to Sebastian et al., which
is incorporated herein by reference in its entirety.
[0020] Referring to FIG. 1, a representative smoking article 10 in
the form of a cigarette is shown. The smoking article 10 has a
rod-like shape, and includes a lighting end 14 and a mouth end
18.
[0021] At the lighting end 14 is positioned a longitudinally
extending, generally cylindrical smokable lighting end segment 22,
incorporating smokable material 26. A representative smokable
material 26 can be a plant-derived material (e.g., tobacco material
in cut filler form). An exemplary cylindrical smokable lighting end
segment 22 includes a charge or roll of the smokable material 26
(e.g., tobacco cut filler) wrapped or disposed within, and
circumscribed by, a paper wrapping material 30. As such, the
longitudinally extending outer surface of that cylindrical smokable
lighting end segment 22 is provided by the wrapping material
30.
Preferably, both ends of the segment 22 are open to expose the
smokable material 26. The smokable lighting end segment 22 can be
configured so that smokable material 26 and wrapping material 30
each extend along the entire length thereof.
[0022] Located downstream from the smokable lighting end segment 22
is a longitudinally extending, generally cylindrical heat
generation segment 35. The heat generation segment 35 includes a
heat source 40 circumscribed by insulation 42, which may be
coaxially encircled by wrapping material 45. The heat source 40
preferably is configured to be activated by combustion of the
smokable material 26. Ignition and combustion of the smoking
material preferably provide a user with a desirable experience
(with respect at least to flavor and time taken to light the
smoking article 10). The heat generated as the smokable material is
consumed most preferably is sufficient to ignite or otherwise
activate the heat source 40.
[0023] The heat source 40 may include a combustible fuel element
that has a generally cylindrical shape and can incorporate a
combustible carbonaceous material. Carbonaceous materials generally
have high carbon contents. Preferred carbonaceous materials are
composed predominately of carbon, typically have carbon contents of
greater than about 60 percent, generally greater than about 70
percent, often greater than about 80 percent, and frequently
greater than about 90 percent, on a dry weight basis. Fuel elements
can incorporate components other than combustible carbonaceous
materials (e.g., tobacco components, such as powdered tobaccos or
tobacco extracts; flavoring agents; salts, such as sodium chloride,
potassium chloride and sodium carbonate; heat stable graphite
fibers; iron oxide powder; glass filaments; powdered calcium
carbonate; alumina granules; ammonia sources, such as ammonia
salts; and/or binding agents, such as guar gum, ammonium alginate
and sodium alginate). A representative fuel element has a length of
about 12 mm and an overall outside diameter of about 4.2 mm. A
representative fuel element can be extruded or compounded using a
ground or powdered carbonaceous material, and has a density that is
greater than about 0.5 g/cm.sup.3, often greater than about 0.7
g/cm.sup.3, and frequently greater than about 1 g/cm.sup.3, on a
dry weight basis. See, for example, the types of fuel element
components, formulations and designs set forth in U.S. Pat. No.
5,551,451 to Riggs et al. and U.S. Pat. No. 7,836,897 to Borschke
et al., which are incorporated herein by reference in their
entirety. Particular embodiments of fuel elements are described
below with reference to FIG. 3.
[0024] Another embodiment of a fuel element 40 may include a foamed
carbon monolith formed in a foam process. In another embodiment,
the fuel element 40 may be co-extruded with a layer of insulation
42, thereby reducing manufacturing time and expense. Still other
embodiments of fuel elements may include those of the types
described in U.S. Pat. No. 4,922,901 to Brooks et al. or U.S. Pat.
App. Pub. No. 2009/0044818 to Takeuchi et al., each of which is
incorporated herein by reference.
[0025] A representative layer of insulation 42 can comprise glass
filaments or fibers. The insulation 42 can act as a jacket that
assists in maintaining the heat source 40 firmly in place within
the smoking article 10. The insulation 42 can be provided as a
multi-layer component including an inner layer or mat 47 of
non-woven glass filaments, an intermediate layer of reconstituted
tobacco paper 48, and an outer layer of non-woven glass filaments
49. These may be concentrically oriented or each overwrapping
and/or circumscribing the heat source.
[0026] In one embodiment, the inner layer 47 of insulation may
include a variety of glass or non-glass filaments or fibers that
are woven, knit, or both woven and knit (such as, for example,
so-called 3-D woven/knit hybrid mats). When woven, an inner layer
47 may be formed as a woven mat or tube. A woven or knitted mat or
tube can provide superior control of air flow with regard to
evenness across the insulation layer (including as any
thermal-related changes may occur to the layer). Those of skill in
the art will appreciate that a woven, knit, or hybrid material may
provide more regular and consistent air spaces/gaps between the
filaments or fibers as compared to a non-woven material which is
more likely to have irregularly closed and open spaces that may
provide comparatively non-uniform and/or decreased air-flow.
Various other insulation embodiments may be molded, extruded,
foamed, or otherwise formed. Particular embodiments of insulation
structures may include those described in U.S. Pat. App. Publ. No.
20120042885 to Stone et al., which is incorporated by reference
herein in its entirety.
[0027] Preferably, both ends of the heat generation segment 35 are
open to expose the heat source 40 and insulation 42 to the adjacent
segments. The heat source 40 and the surrounding insulation 42 can
be configured so that the length of both materials is co-extensive
(i.e., the ends of the insulation 42 are flush with the respective
ends of the heat source 40, and particularly at the downstream end
of the heat generation segment). Optionally, though not necessarily
preferably, the insulation 42 may extend slightly beyond (e.g.,
from about 0.5 mm to about 2 mm beyond) either or both ends of the
heat source 40. Moreover, smoke produced when the smokable lighting
end segment 22 is burned during use of the smoking article 10 can
readily pass through the heat generation segment 35 during draw by
the smoker on the mouth end 18.
[0028] The heat generation segment 35 preferably is positioned
adjacent to the downstream end of the smokable lighting end segment
22 such that those segments are axially aligned in an end-to-end
relationship, preferably abutting one another, but with no barrier
(other than open air-space) therebetween. The close proximity of
the heat generation segment 35 and the smokable lighting end
segment 22 provides for an appropriate heat exchange relationship
(e.g., such that the action of burning smokable material within the
smokable lighting end segment 22 acts to ignite the heat source of
the heat generation segment 35). The outer cross-sectional shapes
and dimensions of the smokable lighting end and heat generation
segments 22, 35, when viewed transversely to the longitudinal axis
of the smoking article, can be essentially identical to one another
(e.g., both appear to have a cylindrical shape, each having
essentially identical diameters).
[0029] The cross-sectional shape and dimensions of the heat
generation segment 35, prior to burning, can vary. Preferably, the
cross-sectional area of the heat source 40 makes up about 10
percent to about 35 percent, often about 15 percent to about 25
percent of the total cross-sectional area of that segment 35; while
the cross-sectional area of the outer or circumscribing region
(comprising the insulation 42 and relevant outer wrapping
materials) makes up about 65 percent to about 90 percent, often
about 75 percent to about 85 percent of the total cross-sectional
area of that segment 35. For example, for a cylindrical smoking
article having a circumference of about 24 mm to about 26 mm, a
representative heat source 40 has a generally circular
cross-sectional shape with an outer diameter of about 2.5 mm to
about 5 mm, often about 3 mm to about 4.5 mm.
[0030] A longitudinally extending, cylindrical aerosol-generating
segment 51 is located downstream from the heat generation segment
35. The aerosol-generating segment 51 includes a substrate material
55 that, in turn, acts as a carrier for an aerosol-forming agent or
material (not shown). For example, the aerosol-generating segment
51 can include a reconstituted tobacco material that includes
processing aids, flavoring agents, and glycerin.
[0031] The foregoing components of the aerosol-generating segment
51 can be disposed within, and circumscribed by, a wrapping
material 58. The wrapping material 58 can be configured to
facilitate the transfer of heat from the lighting end 14 of the
smoking article 10 (e.g., from the heat generation segment 35) to
components of the aerosol-generating segment 51. That is, the
aerosol-generating segment 51 and the heat generation segment 35
can be configured in a heat exchange relationship with one another.
The heat exchange relationship is such that sufficient heat from
the heat source 40 is supplied to the aerosol-formation region to
volatilize aerosol-forming material for aerosol formation. In some
embodiments, the heat exchange relationship is achieved by
positioning those segments in close proximity to one another. A
heat exchange relationship also can be achieved by extending a heat
conductive material from the vicinity of the heat source 40 into or
around the region occupied by the aerosol-generating segment 51.
Particular embodiments of substrates may include those described
below or those described in U.S. Pat. App. Pub. No. 2012/0042885 to
Stone et al., which is incorporated by reference herein in its
entirety.
[0032] A representative wrapping material 58 for the substrate
material 55 may include heat conductive properties to conduct heat
from the heat generation segment 35 to the aerosol-generating
segment 51, in order to provide for the volatilization of the
aerosol forming components contained therein. The substrate
material 55 may be about 10 mm to about 22 mm in length, with
certain embodiments being about 11 mm to about 12 mm in length, and
other embodiments ranging up to about 21 mm.
[0033] The substrate material 55 can be provided from a blend of
flavorful and aromatic tobaccos in cut filler form. Those tobaccos,
in turn, can be treated with aerosol-forming material and/or at
least one flavoring agent. The substrate material can be provided
from a processed tobacco (e.g., a reconstituted tobacco
manufactured using cast sheet or papermaking types of processes) in
cut filler form. Certain cast sheet constructions may include about
270 to about 300 mg of tobacco per 10 mm of linear length. That
tobacco, in turn, can be treated with, or processed to incorporate,
aerosol-forming material and/or at least one flavoring agent, as
well as a burn retardant (e.g., diammonium phosphate or another
salt) configured to help prevent ignition and/or scorching by the
heat-generation segment. A metal inner surface of the wrapping
material 58 of the aerosol-generating segment 51 can act as a
carrier for aerosol-forming material and/or at least one flavoring
agent.
[0034] In other embodiments, the substrate 55 may include a tobacco
paper or non-tobacco gathered paper formed as a plug section. The
plug section may be loaded with aerosol-forming materials,
flavorants, tobacco extracts, or the like in a variety of forms
(e.g., microencapsulated, liquid, powdered). A burn retardant
(e.g., diammonium phosphate or another salt) may be applied to at
least a distal/lighting-end portion of the substrate to help
prevent ignition and/or scorching by the heat-generation
segment.
[0035] In these and/or other embodiments, the substrate 55 may
include pellets or beads formed from marumarized and/or
non-marumarized tobacco. Marumarized tobacco is known, for example,
from U.S. Pat. No. 5,105,831 to Banerjee, et al., which is
incorporated herein by reference. Marumarized tobacco may include
about 20 to about 50 percent (by weight) tobacco blend in powder
form, with glycerol (at about 20 to about 30 percent by weight),
calcium carbonate (generally at about 10 to about 60 percent by
weight, often at about 40 to about 60 percent by weight), along
with binder and flavoring agents. The binder may include, for
example, a carboxymethyl cellulose (CMC), gums (e.g., guar gum),
xanthan, pullulan, or alginates. The beads, pellets, or other
marumarized forms may be constructed in dimensions appropriate to
fitting within a substrate section and providing for optimal air
flow and production of desirable aerosol. A container, such as a
cavity or capsule, may be formed for retaining the substrate in
place within the smoking article. Such a container may be
beneficial to contain, for example, pellets or beads of marumarized
and/or non-marumarized tobacco. The container may be formed using
wrapping materials as further described below. The term "tobacco
pellets" is defined herein to include beads, pellets, or other
discrete small units of tobacco that may include marumarized and/or
non-marumarized tobacco. The tobacco pellets may have smooth,
regular outer shapes (e.g., spheres, cylinders, ovoids, etc.)
and/or they may have irregular outer shapes. In one example, the
diameter of each tobacco pellet may range from less than about 1 mm
to about 2 mm. The tobacco pellets may at least partially fill a
substrate cavity of a smoking article as described herein. In one
example, the volume of the substrate cavity may range from about
500 mm.sup.3 to about 700 mm.sup.3 (e.g., a substrate cavity of a
smoking article where the cavity diameter is about 7.5 to about 7.8
mm, and the cavity length is about 11 to about 15 mm, with the
cavity having a generally cylindrical geometry). In one example,
the mass of the tobacco pellets within the substrate cavity may
range from about 200 mg to about 500 mg.
[0036] In still other embodiments, the substrate 55 may be
configured as a monolithic substrate. The monolithic substrate may
be formed as described in U.S. Pat. App. Publ. No. 2012/0042885 to
Stone et al., which is incorporated herein by reference in its
entirety. The substrate may include or be constructed from an
extruded material. The substrate also may be formed by press-fit or
molding/casting. Thus, the generic term "monolithic substrate" may
include a substrate formed by extrusion or by one of those other
methods.
[0037] For preferred smoking articles, both ends of the
aerosol-generating segment 51 are open to expose the substrate
material 55 thereof. Components of the aerosol produced by burning
the smokable lighting end segment 22 during use of the smoking
article can readily pass through the aerosol-generating segment 51
during draw on the mouth end 18.
[0038] Together, the heat generating segment 35 and the
aerosol-generating segment 51 form an aerosol-generation system 60.
The aerosol-generating segment 51 is positioned adjacent to the
downstream end of the heat generation segment 35 such that those
segments 51, 35 are axially aligned in an end-to-end relationship.
Those segments can abut one another, or be positioned in a slightly
spaced apart relationship, which may include a buffer region 53.
The outer cross-sectional shapes and dimensions of those segments,
when viewed transversely to the longitudinal axis of the smoking
article 10, can be essentially identical to one another. The
physical arrangement of those components preferably is such that
heat is transferred (e.g., by means that includes conductive and
convective heat transfer) from the heat source 40 to the adjacent
substrate material 55, throughout the time that the heat source is
activated (e.g., burned) during use of the smoking article 10.
[0039] A buffer region 53 may reduce potential scorching or other
thermal degradation of portions of the aerosol-generating segment
51. The buffer region 53 may mainly include empty air space, or it
may be partially or substantially completely filled with a
non-combustible material such as, for example, metal, organic,
inorganic, ceramic, or polymeric materials, or any combination
thereof. The buffer regions may be from about 1 mm to about 10 mm
or more in thickness, but often will be about 2 mm to about 5 mm in
thickness.
[0040] The components of the aerosol-generation system 60 and the
smokable lighting end segment 22 preferably are attached to one
another, and secured in place using an overwrap material 64. For
example, the overwrap material 64 can include a paper wrapping
material or a laminated paper-type material that circumscribes each
of the heat generation segment 35, at least a portion of outer
longitudinally extending surface of the aerosol-generating segment
51, and at least a portion of the lighting end segment 22 that is
adjacent to the heat generation segment. The inner surface of the
overwrap material 64 may be secured to the outer surfaces of the
components it circumscribes by a suitable adhesive. Preferably, the
overwrap material 64 extends over a significant portion of the
length of the smokable lighting end segment 22.
[0041] The smoking article 10 preferably includes a suitable
mouthpiece such as, for example, a filter element 65, positioned at
the mouth end 18 thereof. The filter element 65 preferably is
positioned at one end of the cigarette rod adjacent to one end of
the aerosol-generating segment 51, such that the filter element 65
and the aerosol-generating segment 51 are axially aligned in an
end-to-end relationship, abutting one another but without any
barrier therebetween. Preferably, the general cross-sectional
shapes and dimensions of those segments 51, 65 are essentially
identical to one another when viewed transversely to the
longitudinal axis of the smoking article. The filter element 65 may
include filter material 70 that is overwrapped along the
longitudinally extending surface thereof with circumscribing plug
wrap material 72. In one example, the filter material 70 includes
plasticized cellulose acetate tow, while in some examples the
filter material may further include activated charcoal in an amount
from about 20 to about 80 mg disposed as a discrete charge or
dispersed throughout the acetate tow in a "Dalmatian type" filter.
Both ends of the filter element 65 preferably are open to permit
the passage of aerosol therethrough. The aerosol-generating system
60 preferably is attached to the filter element 65 using tipping
material 78. The filter element 65 may also include a crushable
flavor capsule of the type described in U.S. Pat. No. 7,479,098 to
Thomas et al. and U.S. Pat. No. 7,793,665 to Dube et al.; and U.S.
Pat. App. Pub. No. 2009/0194118 to Ademe et al., which are
incorporated herein by reference in their entirety.
[0042] The smoking article 10 may include an air dilution means,
such as a series of perforations 81, each of which may extend
through the filter element tipping material 78 and plug wrap
material 72 in the manner shown, and/or which may extend to or into
the substrate 55.
[0043] The overall dimensions of the smoking article 10, prior to
burning, can vary. Typically, smoking articles 10 are cylindrically
shaped rods having circumferences of about 20 mm to about 27 mm,
have overall lengths of about 70 mm to about 130 mm--often about 83
mm to about 100 mm. Smokable lighting end segments 22 typically
have lengths of about 3 mm to about 15 mm, but can be up to about
30 mm. The aerosol-generation system 60 has an overall length that
can vary from about 20 mm to about 65 mm. The heat generation
segment 35 of the aerosol-generation system 60 may have a length of
about 5 mm to about 30 mm; and the aerosol-generating segment 51 of
the aerosol-generation system 60 may have an overall length of
about 10 mm to about 60 mm.
[0044] The amount of smokable material 26 employed to manufacture
the smokable lighting end segment 22 can vary. Typically, the
smokable lighting end segment 22, manufactured predominantly from
tobacco cut filler, includes at least about 20 mg, generally at
least about 50 mg, often at least about 75 mg, and frequently at
least 100 mg, of tobacco material, on a dry weight basis. The
packing density of the smokable material 26 within the smokable
lighting end segment 22 preferably will be less than the density of
the fuel element (e.g., about 100 to about 400 mg/cm.sup.3).
Preferably, the smokable lighting end segment 22 essentially
comprises smokable material 26, and does not include a carbonaceous
fuel element component.
[0045] The combined amount of aerosol-forming agent and substrate
material 55 employed in the aerosol-generating segment 51 can vary.
The material preferably may be employed so as to fill the
appropriate section of the aerosol-generating segment 51 (e.g., the
region within the wrapping material 58 thereof) at a packing
density of about 100 to about 400 mg/cm.sup.3.
[0046] During use, the smoker lights the lighting end 14 of the
smoking article 10 using a match or cigarette lighter, in a manner
similar to the way that conventional smoking articles are lit. As
such, the smokable material 26 of the smokable lighting end segment
22 begins to burn. The mouth end 18 of the smoking article 10 is
placed in the lips of the smoker. Thermal decomposition products
(e.g., components of tobacco smoke) generated by the burning
smokable material 26 are drawn through the smoking article 10,
through the filter element 65, and into the mouth of the smoker.
That is, when smoked, the smoking article yields visible mainstream
aerosol that resembles the mainstream tobacco smoke of traditional
cigarettes that burn tobacco cut filler.
[0047] Burning the smokable lighting end segment 22 heats the fuel
element 40 of the heat generation segment 35 such that it
preferably will be ignited or otherwise activated (e.g., begin to
burn). The heat source 40 within the aerosol-generation system 60
will burn, and provide heat to volatilize aerosol-forming material
within the aerosol-generating segment 51 as a result of the heat
exchange relationship between those two segments. Certain preferred
heat sources 40 will not experience volumetric decrease during
activation, while others may degrade in a manner that reduces their
volume. Preferably, the components of the aerosol-generating
segment 51 do not experience thermal decomposition (e.g., charring
or burning) to any significant degree. Volatilized components are
entrained in the air that is drawn through the aerosol-generating
region 51. The aerosol so formed will be drawn through the filter
element 65, and into the mouth of the smoker.
[0048] During certain periods of use, aerosol formed within the
aerosol-generating segment 51, along with the aerosol (i.e., smoke)
formed as a result of the thermal degradation of the smokable
material 26 within the smokable lighting end segment 22, will be
drawn through the filter element 65 and into the mouth of the
smoker. Thus, the mainstream aerosol produced by the smoking
article 10 includes tobacco smoke produced by the thermal
decomposition of the tobacco cut filler as well as by the
volatilized aerosol-forming material. For early puffs (i.e., during
and shortly after lighting), most of the mainstream aerosol results
from thermal decomposition of the smokable lighting end segment 22.
For later puffs (i.e., after the smokable lighting end segment 22
has been consumed and the heat source 40 of the aerosol-generation
system 60 has been ignited), most of the mainstream aerosol that is
provided will be produced by the aerosol-generation system 60. When
the smokable material 26 has been consumed, and the heat source 40
extinguishes, the use of the smoking article is ceased (i.e., the
smoking experience is finished).
[0049] Referring to FIG. 2, a representative smoking article 10 in
the form of a cigarette is shown. The smoking article 10 includes a
heat generation segment 35 located at the lighting end 14, a filter
segment 65 located at the other end (mouth end 18), and an
aerosol-generating segment 51 (which may incorporate tobacco) that
is located in between those two segments near the lighting end. The
heat generation segment 35 of FIG. 2 can incorporate a generally
cylindrical carbonaceous heat source circumscribed by insulation
similar to what is shown in FIG. 1. The composition and dimensions
of the various segments of the smoking article 10 in FIG. 2 are
generally similar in manner with respect to those set forth
previously with reference to FIG. 1, but without a charge of
smokable material at the distal/lighting end, such that the fuel
element is ignited directly rather than by a smokable material that
was ignited and burned.
[0050] A filter element 65 preferably is attached to the cigarette
rod so formed using a tipping material 78, in the general manner
set forth previously with reference to FIG. 1. The smoking article
optionally can be air-diluted by providing appropriate perforations
81 in the vicinity of the mouth end region 18, as is known in the
art. Filters may include materials and may be manufactured by
methods such as, for example, those disclosed in U.S. Pat. No.
7,740,019 to Nelson et al. and U.S. Pat. No. 7,972,254 to Stokes et
al.; and U.S. Pat. Publ. Nos. 2008/0142028 to Fagg, et al.;
2009/0288672 to Hutchens et al.; and 2009/0090372 to Thomas et al.,
each of which is incorporated herein by reference.
[0051] Flavor may be provided or enhanced by capsule or
microcapsule materials on or within the substrate material 55 of
the aerosol-generating segment 51 (FIG. 1 may be considered to have
microcapsules present therein for illustrative purposes), the
wrapping materials, the filter element 65, or any other component
capable of holding and releasing flavorants, preferably with
minimal thermal degradation that would undesirably alter the
flavor. Other flavor components associated with a filter may also
be used; see, for example, U.S. Pat. No. 5,724,997 to Fagg, et
al.
[0052] Cigarettes described with reference to FIG. 2 may be used in
much the same manner as those cigarettes commercially marketed
under the trade name "Eclipse" by R. J. Reynolds Tobacco Company.
See also the "Steam Hot One" cigarette marketed by Japan Tobacco
Inc.
[0053] Smokable materials of the smokable lighting end segment most
preferably incorporate tobacco of some form. Preferred smokable
materials are composed predominantly of tobacco, based on the dry
weights of those materials. That is, the majority of the dry weight
of those materials, and the majority of the weight of a mixture
incorporating those materials (including a blend of materials, or
materials having additives applied thereto or otherwise
incorporated therein) are provided by tobacco of some form. Those
materials may be made all of tobacco material, and not incorporate
any non-tobacco fillers, substitutes or extenders. The smokable
material can be treated with tobacco additives that are
traditionally used for the manufacture of cigarettes, such as
casing and/or top dressing components. These tobacco components may
be understood with reference to the examples and references set
forth in U.S. Pat. App. Pub. No. 2007/0215167 to Crooks, et al.,
which is incorporated herein by reference in its entirety.
[0054] Fuel elements of the heat generation segment may vary.
Suitable fuel elements, and representative components, designs and
configurations thereof, and manners and methods for producing those
fuel elements and the components thereof, are set forth in U.S.
Pat. No. 4,714,082 to Banerjee et al.; U.S. Pat. No. 4,756,318 to
Clearman et al.; U.S. Pat. No. 4,881,556 to Clearman et al.; U.S.
Pat. No. 4,989,619 to Clearman et al.; U.S. Pat. No. 5,020,548 to
Farrier et al.; U.S. Pat. No. 5,027,837 to Clearman et al.; U.S.
Pat. No. 5,067,499 to Banerjee et al.; U.S. Pat. No. 5,076,297 to
Farrier et al.; U.S. Pat. No. 5,099,861 to Clearman et al.; U.S.
Pat. No. 5,105,831 to Banerjee et al.; U.S. Pat. No. 5,129,409 to
White et al.; U.S. Pat. No. 5,148,821 to Best et al.; U.S. Pat. No.
5,156,170 to Clearman et al.; U.S. Pat. No. 5,178,167 to Riggs et
al.; U.S. Pat. No. 5,211,684 to Shannon et al.; U.S. Pat. No.
5,247,947 to Clearman et al.; U.S. Pat. No. 5,345,955 to Clearman
et al.; U.S. Pat. No. 5,469,871 to Barnes et al.; U.S. Pat. No.
5,551,451 to Riggs; U.S. Pat. No. 5,560,376 to Meiring et al.; U.S.
Pat. No. 5,706,834 to Meiring et al.; and U.S. Pat. No. 5,727,571
to Meiring et al.; and U.S. Pat. App. Pub. Nos. 2005/0274390 and
2010/0065075 to Banerjee et al.; which are incorporated herein by
reference.
[0055] Fuel elements often comprise carbonaceous material and may
include ingredients such as graphite or alumina, as well as high
carbon content carbonaceous material. Carbonaceous fuel elements
include the type that have been incorporated within those
cigarettes commercially marketed under the trade names "Premier"
and "Eclipse" by R. J. Reynolds Tobacco Company. See also the
"Steam Hot One" cigarette marketed by Japan Tobacco Inc. Some other
embodiments of fuel elements are set forth in U.S. Pat. No.
5,178,167 to Riggs et al. and U.S. Pat. No. 5,551,451 to Riggs et
al., both which are incorporated herein by reference in their
entirety, but certain embodiments may lack the sodium, graphite,
and/or calcium carbonate set forth therein. Some fuel element
embodiments may include a foamed carbon monolith. In another
embodiment, the fuel element 40 may be co-extruded with a layer of
insulation 42, thereby reducing manufacturing time and expense.
[0056] Fuel elements may be treated (e.g., dip-coated) with various
precursors (e.g., a metal nitrate or metal oxide) and/or subjected
to heat treatment. Such treatment may provide a reduced CO
concentration in mainstream aerosol generated by a smoking article
including a treated fuel element as compared to a smoking article
including an untreated fuel element. Such fuel elements are further
described in U.S. Pat. App. Publ. 2012/0042885, which is
incorporated herein by reference in its entirety.
[0057] The fuel element preferably will be circumscribed or
otherwise jacketed by insulation, or other suitable material. The
insulation can be configured and employed so as to support,
maintain and retain the fuel element in place within the smoking
article. The insulation may additionally be configured such that
drawn air and aerosol can pass readily therethrough. Examples of
insulation materials, components of insulation assemblies,
configurations of representative insulation assemblies within heat
generation segments, wrapping materials for insulation assemblies,
and manners and methods for producing those components and
assemblies, are set forth in U.S. Pat. No. 4,807,809 to Pryor et
al.; U.S. Pat. No. 4,893,637 to Hancock et al.; U.S. Pat. No.
4,938,238 to Barnes et al.; U.S. Pat. No. 5,027,836 to Shannon et
al.; U.S. Pat. No. 5,065,776 to Lawson et al.; U.S. Pat. No.
5,105,838 to White et al.; U.S. Pat. No. 5,119,837 to Banerjee et
al.; U.S. Pat. No. 5,247,947 to Clearman et al.; U.S. Pat. No.
5,303,720 to Banerjee et al.; U.S. Pat. No. 5,345,955 to Clearman
et al.; U.S. Pat. No. 5,396,911 to Casey, III et al.; U.S. Pat. No.
5,546,965 to White; U.S. Pat. No. 5,727,571 to Meiring et al.; U.S.
Pat. No. 5,902,431 to Wilkinson et al.; and U.S. Pat. No. 5,944,025
to Cook et al.; and U.S. Pat. App. Pub. No. 2011/0041861 to
Sebastian et al.; which are incorporated herein by reference.
Insulation assemblies have been incorporated within the types of
cigarettes commercially marketed under the trade names "Premier"
and "Eclipse" by R. J. Reynolds Tobacco Company, and as "Steam Hot
One" cigarette marketed by Japan Tobacco Inc.
[0058] Flame/burn retardant materials and additives useful in
insulation may include silica, carbon, ceramic, metallic fibers
and/or particles. When treating cellulosic or other fibers such
as--for example--cotton, boric acid or various organophosphate
compounds may provide desirable flame-retardant properties. In
addition, various organic or metallic nanoparticles may confer a
desired property of flame-retardancy, as may diammonium phosphate
and/or other salts. Other useful materials may include
organo-phosphorus compounds, borax, hydrated alumina, graphite,
potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and
polyols. Others such as nitrogenous phosphonic acid salts,
mono-ammonium phosphate, ammonium polyphosphate, ammonium bromide,
ammonium chloride, ammonium borate, ethanolammonium borate,
ammonium sulphamate, halogenated organic compounds, thio-urea, and
antimony oxides may be used but are not preferred agents. In each
embodiment of flame-retardant, burn-retardant, and/or
scorch-retardant materials used in insulation, substrate material
and other components (whether alone or in any combination with each
other and/or other materials), the desirable properties most
preferably are provided without undesirable off-gassing or
melting-type behavior.
[0059] An insulation fabric preferably will have sufficient oxygen
diffusion capability to sustain a smoking article such as a
cigarette lit during a desired usage time. Accordingly the
insulation fabric preferably will be porous by virtue of its
construction. In knit, woven, or combined woven and knit
constructions, the required porosity may be controlled by
configuring the assembly machinery to leave sufficient (desirably
sized) gaps between fibers to allow for oxygen diffusion into the
heat source. For non-woven fabrics, which may not be porous enough
to promote evenly sustained combustion, additional porosity may be
achieved by perforations into the insulation by methods known in
the art including, for example, hot or cold pin perforation, flame
perforation, embossing, laser cutting, drilling, blade cutting,
chemical perforation, punching, and other methods. Each of the
buffer and the insulation may include non-glass material that is
woven, knit, or a combination thereof, a foamed metal material, a
foamed ceramic material, a foamed ceramic metal composite, and any
combination thereof, and the material in the insulation may be the
same as or different than that in the buffer.
[0060] The aerosol-forming material can vary, and mixtures of
various aerosol-forming materials can be used, as can various
combinations and varieties of flavoring agents (including various
materials that alter the sensory and/or organoleptic character or
nature of mainstream aerosol of a smoking article), wrapping
materials, mouth-end pieces, filter elements, plug wrap, and
tipping material. Representative types of these components are set
forth in U.S. Pat. App. Pub. No. 2007/0215167 to Crooks, et al.,
which is incorporated herein by reference in its entirety.
[0061] The substrate material can incorporate tobacco of some form,
normally is composed predominantly of tobacco, and can be provided
by virtually all tobacco material. The form of the substrate
material can vary. In some embodiments, the substrate material is
employed in an essentially traditional filler form (e.g., as cut
filler). The substrate material can be otherwise formed into
desired configurations. The substrate material can be used in the
form of a gathered web or sheet, using the types of techniques
generally set forth in U.S. Pat. No. 4,807,809 to Pryor et al,
which is incorporated herein by reference in its entirety. The
substrate material can be used in the form of a web or sheet that
is shredded into a plurality of longitudinally extending strands,
using the types of techniques generally set forth in U.S. Pat. No.
5,025,814 to Raker, which is incorporated herein by reference in
its entirety. The substrate material can have the form of a loosely
rolled sheet, such that a spiral type of air passageway extends
longitudinally through the aerosol-generating segment.
Representative types of tobacco containing substrate materials can
be manufactured from mixtures of tobacco types; or from one
predominant type of tobacco (e.g., a cast sheet-type or paper-type
reconstituted tobacco composed primarily of burley tobacco, or a
cast sheet-type or paper-type reconstituted tobacco composed
primarily of Oriental tobacco).
[0062] The substrate material also can be treated with tobacco
additives of the type that are traditionally used for the
manufacture of cigarettes, such as casing and/or top dressing
components. See, for example, the types of components set forth in
U.S. Pat. Publication 2004/0173229 to Crooks et al, which is
incorporated herein by reference in its entirety.
[0063] The manner by which the aerosol-forming material is
contacted with the substrate material (e.g., the tobacco material)
can vary. The aerosol-forming material can be applied to a formed
tobacco material, or can be incorporated into processed tobacco
materials during manufacture of those materials. The
aerosol-forming material can be dissolved or dispersed in an
aqueous liquid, or other suitable solvent or liquid carrier, and
sprayed onto that substrate material. See, for example, U.S. Patent
Application Pub. No. 2005/0066986 to Nestor et al, which is
incorporated herein by reference in its entirety. The amount of
aerosol-forming material employed relative to the dry weight of
substrate material can vary. Materials including exceedingly high
levels of aerosol-forming material can be difficult to process into
cigarette rods using conventional types of automated cigarette
manufacturing equipment.
[0064] Cast sheet types of materials may incorporate relatively
high levels of aerosol-forming material. Reconstituted tobaccos
manufactured using paper-making types of processes may incorporate
moderate levels of aerosol-forming material. Tobacco strip and
tobacco cut filler can incorporate lower amounts of aerosol-forming
material. Various paper and non-paper substrates including
gathered, laminated, laminated metal/metallic, strips, beads such
as alumina beads, open cell foam, foamed monolith, air permeable
matrices, and other materials can be used within the scope of the
invention. See, for example, U.S. Pat. Nos. 5,183,062; 5,203,355;
and 5,588,446; each to Clearman, and each of which is incorporated
herein by reference.
[0065] In other embodiments, the substrate portion of an
aerosol-generation segment may include or may be constructed from
an extruded or other monolithic material. An extruded substrate may
be formed in the same manner as described herein with reference to
other extruded components. The extruded or other monolithic
substrate may include, or may be essentially comprised of, tobacco,
glycerin, water, and binder material. In certain embodiments, a
monolithic substrate may include about 10 to about 90
weight-percent tobacco, about 5 to about 50 weight-percent
glycerin, about 1 to about 30 weight-percent water (before being
dried and cut), and about 0 to about 10 weight-percent binder. It
may also include a filler such as, for example, calcium carbonate
and/or graphite.
[0066] Following extrusion, drying, and cutting to a desired
length, the substrate may be assembled into a segmented smoking
article such as an Eclipse-type cigarette using a manual assembly
method or a cigarette-making machine (e.g., KDF or Protus by Hauni
Maschinenbau AG). Smaller diameter monolithic substrate elements
may be combined by being wrapped, adhered, or otherwise assembled
together for use in a smoking article as described for other
substrate embodiments herein. Preferred substrate wraps include
foil paper, heavy-gauge paper, plug wrap, and/or cigarette
paper.
[0067] In one embodiment, a smoking article may be constructed with
a monolithic substrate 463, described here with reference to FIG.
4, which is a longitudinal section view of a cigarette 410 having a
lighting end 414 and a mouth end 418. The monolithic substrate 463
(which may be used in other embodiments such as, for example, those
discussed with reference to FIGS. 1 and 2) may be formed by any
appropriate extrusion method and is shown with a center-hole 495
extending longitudinally therethrough. The monolithic substrate,
cut to length may comprise about 1/16 to about 5/8 of the total
length of the cigarette, often about 1/10 to about 1/2 thereof
(e.g., a 10 mm, 12 mm, or 50 mm long substrate element in an 85 mm
or 130 mm long cigarette). The substrate segment 455 of the
cigarette body includes a hollow spacing tube 467 disposed between
the substrate 463 and the filter 470. The filter 470 is shown as
constructed with overlying layers of plug wrap 472 and tipping
paper 478. The substrate 463 and tube 467 are surrounded by a
wrapping material 458, which may be configured--for example--as a
heat-conducting material (e.g., foil paper), heavy-gauge paper,
plug wrap, or cigarette paper. A cylindrically-encompassing
wrapping material 464 (such as, for example, cigarette paper or
heavy-gauge paper) may be provided to connect the heat-generation
segment 435, central substrate segment 455, and filter segment 465.
The heat-generation segment 435 and other components may be
constructed as described herein and elsewhere in this and other
embodiments configured to be practiced within the scope of the
present invention.
[0068] In another embodiment, a smoking article may be constructed
with an elongate monolithic substrate 563, described here with
reference to FIG. 5, which is a longitudinal section view of a
cigarette 510 having a lighting end 514 and a mouth end 518. The
elongate monolithic substrate 563 (which may be used in other
embodiments) may be formed by any appropriate extrusion method and
is shown with a center-hole 595 extending longitudinally
therethrough. The filter 570 is shown as constructed with overlying
layers of plug wrap 572 and tipping paper 578. The substrate 563 is
surrounded by a wrapping material 558, which may be configured--for
example--as a heat-conducting material (e.g., foil paper),
heavy-gauge paper, plug wrap, or cigarette paper. A
cylindrically-encompassing wrapping material 564 (such as, for
example, cigarette paper or heavy-gauge paper) may be provided to
connect the heat-generation segment 535, central substrate segment
555 (consisting essentially of the substrate in this embodiment),
and filter segment 565. The heat-generation segment 535 and other
components may be constructed as described herein and elsewhere in
this and other embodiments configured to be practiced within the
scope of the present invention.
[0069] In one embodiment, a smoking article may be constructed with
a monolithic substrate 663, described here with reference to FIG.
6, which is a longitudinal section view of a cigarette 610 having a
lighting end 614 and a mouth end 618. The monolithic substrate 663
(which may be used in other embodiments) may be formed by any
appropriate extrusion method and is shown with a center-hole 695
extending longitudinally therethrough. The cigarette body includes
a tobacco rod 669 disposed between the substrate 663 and the filter
670. The filter 670 is shown as constructed with overlying layers
of plug wrap 672 and tipping paper 678. The substrate segment 655,
formed by the substrate 663 and tobacco rod 669, is surrounded by a
wrapping material 658, which may be configured--for example--as a
heat-conducting material (e.g., foil paper), heavy-gauge paper,
plug wrap, or cigarette paper. A cylindrically-encompassing
wrapping material 664 (such as, for example, cigarette paper or
heavy-gauge paper) may be provided to connect the heat-generation
segment 635, central substrate segment 655, and filter segment 665.
The heat-generation segment 635 and other components may be
constructed as described herein and elsewhere in this and other
embodiments configured to be practiced within the scope of the
present invention.
[0070] In another embodiment, a smoking article may be constructed
with a substrate 763 including tobacco pellets, described here with
reference to FIG. 7, which is a longitudinal section view of a
cigarette 710 having a lighting end 714 and a mouth end 718. The
substrate 763 (which may be used in other embodiments) may be
formed by any appropriate method, such as a marumarization method.
The cigarette body includes a tobacco rod 769 disposed between the
substrate 763 and the filter 770. The filter 770 is shown as
constructed with overlying layers of plug wrap 772 and tipping
paper 778. The heat-generation segment 735 and other components may
be constructed as described herein and elsewhere in this and other
embodiments configured to be practiced within the scope of the
present invention.
[0071] The substrate 763 may be contained within a substrate cavity
756. The substrate cavity 756 may be formed by the heat-generation
segment 735 at one end, the tobacco rod 769 at the opposite end,
and a wrapping material 764 around the circumference of at least
the substrate (and--in some embodiments--extending along an entire
length from the filter to the lighting end). A cylindrical
container structure (not shown) may circumferentially encompass the
substrate cavity 756 within the wrapping material 764 and between
the heat-generation segment 735 at one end and the tobacco rod 769
at the opposite end. The heat-generation segment 735 and the
tobacco rod 769 may be joined to one another by the wrapping
material 764. To that end, the wrapping material 764 may
circumscribe at least a downstream portion of the heat-generation
segment 735 and at least an upstream portion of the tobacco rod
769. The heat-generation segment 735 and the tobacco rod 769 may be
spaced longitudinally from one another. In other words, the
heat-generation segment 735 and the tobacco rod 769 may not be in
abutting contact with one another. The substrate cavity 756 may be
defined by a space extending longitudinally within the wrapping
material 764 between the downstream end of the heat-generation
segment 735 and the upstream end of the tobacco rod 769 as shown in
FIG. 7. The substrate 763 may be positioned within the substrate
cavity 756. For example, the substrate cavity 756 may be at least
partially filled with tobacco pellets. The substrate cavity 756 may
contain the substrate 763 to prevent migration of the tobacco
pellets.
[0072] The wrapping material 764 may be configured, for example, as
a heat-conducting material (e.g., foil paper), insulating material,
heavy-gauge paper, plug wrap, cigarette paper, tobacco paper, or
any combination thereof. Additionally, or alternatively, the
wrapping material 764 may include foil, ceramic, ceramic paper,
carbon felt, glass mat, or any combination thereof. Other wrapping
materials known or developed in the art may be used alone or in
combination with one or more of these wrapping materials. In one
embodiment, the wrapping material 764 may include a paper material
having strips or patches of foil laminated thereto. The wrapping
material 764 may include a paper sheet 783. The paper sheet 783 may
be sized and shaped to circumscribe the heat-generation segment
735, the substrate cavity 756, and the tobacco rod 769 as described
above. To that end, the paper sheet 783 may be substantially
rectangular in shape with a length extending along the longitudinal
direction of the smoking article and a width extending in a
direction transverse to the longitudinal direction. The width of
the paper sheet 783 may be slightly larger than the circumference
of the smoking article 710 so that the paper sheet may be formed
into a tube or a column defining an outer surface of the smoking
article. For example, the width of the paper sheet 783 may be from
about 18 to about 29 mm. The length of the paper sheet 783 may be
sufficient to extend longitudinally along an entire length of the
substrate cavity 764 and to overlap the heat-generation segment 735
and the tobacco rod 769. For example, the length of the paper sheet
783 may be about 50 to about 66 mm. The paper sheet 783 may have a
length sufficient to overlap substantially an entire length of the
tobacco rod 769 as shown in FIG. 7. In one example, the paper sheet
(or other wrapping material) may have a thickness of about 1 mil to
about 6 mil (about 0.025 mm to about 0.15 mm).
[0073] A foil strip or patch 784 may be laminated to the paper
sheet 783 to form a laminated coated region. The foil strip 784 may
have a width extending along substantially the entire width of the
paper sheet 783 to circumscribe substantially the entire
circumference of the heat-generation segment 735, the substrate
cavity 764, and the tobacco rod 769 as further described below. The
foil strip 784 also may have a length extending along a portion of
the length of the paper sheet 783. Preferably, the foil strip 784
may extend along a sufficient portion of the length of the paper
sheet 783 such that the foil strip extends along the entire length
of the substrate cavity 756 and overlaps at least a portion of the
heat-generation segment 735 and the tobacco rod 769. For example,
the length of the foil strip 784 may be from about 16 to about 20
mm. In one example, the foil strip may have a thickness of about
0.0005 mm to about 0.05 mm.
[0074] The foil strip may be laminated on an interior or an
exterior surface of the paper sheet. The foil strip may be
laminated on the paper sheet using any now known or future
developed technique including, for example, heat laminating. The
foil strip may be laminated on the paper sheet using any now known
or future developed adhesive. In one example, the adhesive may be
configured as a cold glue adhesive of the type used to secure
tipping materials to other components of a cigarette. The foil
strip may be laminated or patched to the paper sheet with or
without a lubricant. Preferably, the foil strip may be laminated to
the interior surface of the paper sheet (e.g., the surface of the
paper sheet that faces toward the substrate cavity) to contact the
heat-generation segment, the substrate material, and/or the tobacco
rod. The laminated paper or other wrapping material may be
constructed in accordance with the disclosure of U.S. Pat. No.
6,849,085 to Marton, which is incorporated herein by reference in
its entirety, or in accordance with other appropriate methods
and/or materials. For example, the foil strip may circumferentially
encompass and extend lengthwise along at least a lengthwise portion
of the substrate cavity and may overlap at least a lengthwise
portion of the heat generation segment and/or a lengthwise portion
of the tobacco rod. The foil strip may enhance heat transfer
between the heat-generation segment 735 and the substrate 763. Such
enhanced heat transfer may aid in volatilizing the aerosol-forming
material in the substrate 763 for aerosol formation. To that end,
the foil strip 784 may be formed from a heat conducting material.
The foil strip 784 may be formed from any heat conducting material
including, for example, tin, aluminum, copper, gold, brass, other
thermoconductive materials, and/or any combination thereof. In this
manner, the substrate cavity 756 may be defined by a foil-lined
paper tube or column formed by the wrapping material 764. The
wrapping material may include a registered facing of the foil strip
at a discrete location on the wrapping material.
[0075] An intermediate segment of a smoking article may include a
heat-generation segment, a substrate segment (e.g., a monolithic
substrate or a substrate cavity including pellets or beads of
substrate material), and a tobacco rod. It may be desirable to
provide such an intermediate segment from so-called "two-up" rods
that may be handled using conventional-type or suitably modified
cigarette rod handling devices, such as tipping devices available
as Lab MAX, MAX, MAX S or MAX 80 from Hauni-Werke Korber & Co.
KG. See, for example, the types of devices set forth in U.S. Pat.
No. 3,308,600 to Erdmann et al.; U.S. Pat. No. 4,281,670 to
Heitmann et al.; U.S. Pat. No. 4,280,187 to Reuland et al.; U.S.
Pat. No. 4,850,301 to Greene, Jr. et al.; U.S. Pat. No. 6,229,115
to Vos et al.; U.S. Pat. No. 7,434,585 to Holmes; and U.S. Pat. No.
7,296,578 to Read, Jr.; and U.S. Pat. Appl. Pub. No. 2006/0169295
to Draghetti, each of which is incorporated by reference
herein.
[0076] For example, FIG. 8 illustrates a two-up rod that may be
produced in the process of manufacturing a smoking article 710 of
FIG. 7, or other smoking article described herein. The two-up rod
may include two intermediate segments as described above, the
intermediate segments being joined to one another at a common
tobacco rod. The two-up rod may include two heat-generation
segments 835a, 835b positioned at opposite longitudinal ends
thereof. A tobacco rod 869 may be substantially centered along the
longitudinal axis of the rod. The tobacco rod 869 may include two
portions 869a, 869b each associated with one intermediate segment.
The tobacco rod 869 and the two heat-generation segments 835a, 835b
may be joined to one another with wrapping material 864 as
described above with reference to FIG. 7. A substrate cavity 856a
may be defined within the wrapping material 864 between the
heat-generation segment 835a and the tobacco rod 869. A substrate
863a may be contained within the substrate cavity 856a. Likewise, a
substrate cavity 856b may be defined within the wrapping material
864 between the heat-generation segment 835b and the tobacco rod
869. A substrate 863b may be contained within the substrate cavity
856b. The wrapping material 864 may include a paper sheet 883 with
foil strips 884a, 884b laminated thereto. The foil strips may be
generally aligned with the substrate cavities as described above
with reference to FIG. 7. The rod may be severed at about its
longitudinal center to form two intermediate segments, each
generally configured as described above. A tobacco rod, a hollow
tube, and/or a filter element may be attached to the downstream end
of each intermediate segment by any means to form a smoking article
as described above. The method may include providing the wrapping
material circumscribing at least a portion of the heat generation
segment, the substrate cavity, the tobacco rod, the second
substrate cavity, and at least a portion of the second heat
generation segment, a second foil strip of the wrapping material
circumscribing the second substrate cavity, wherein the foil strip
and the second foil strip are registered at a discrete interval
apart from each other, said interval calibrated to accurately and
repeatably dispose the foil strip and the second foil strip at a
desired location relative to the substrate cavity, the second
substrate cavity, the heat generation segment, and the second heat
generation segment.
[0077] Such a two-up rod and/or an intermediate segment may
facilitate handling of the substrate material during manufacturing
of a smoking article. For example, a two-up rod and/or an
intermediate segment may be processed using standard processing
equipment as described above while retaining the tobacco pellets
substrate 863 between the heat generation segment 835 and the
tobacco rod 869 and within the substrate cavity 856. In other
words, the tobacco pellets substrate may be contained within the
two-up rod and/or intermediate segment so that further processing
may be completed while avoiding migration and/or loss of the
tobacco pellets substrate.
[0078] The wrapping material 864 may be provided as a continuous
tape of material having foil strips 884 laminated thereto in a
repeating pattern. FIG. 9 illustrates a portion of the tape of
wrapping material 864 including one repeat unit of the repeating
pattern. In certain preferred embodiments, foil strips 884 may be
precisely registered along the wrapping material 864 such that each
foil strip will align with a substrate cavity as described above
when the wrapping material is used to form the two-up rods also as
described above.
[0079] In one example, a repeat unit of the repeating pattern may
include a series of segments extending in a longitudinal direction
along the wrapping material 864. A first segment 901 may include
unlaminated paper. In other words, the first segment 901 may
include paper material without a foil strip laminated thereto. The
first segment may have a length of about 4 to about 8 mm. A second
segment 902 may extend longitudinally from the first segment 901
and may include foil laminated paper. In other words, the second
segment 902 may include paper material with a foil strip laminated
thereto, such that the paper material (or other wrapping material)
is continuous, with precisely registered foil strips laminated
thereto at discrete predetermined location intervals. The second
segment 902 may have a length of about 16 to about 20 mm. A third
segment 903 may extend longitudinally from the second segment 902
and may include unlaminated paper. The third segment 903 may have a
length of about 14 to about 18 mm. A fourth segment 904 may extend
longitudinally from the third segment 903 and may include foil
laminated paper. The fourth segment 904 may have a length of about
16 to about 20 mm.
[0080] The repeat unit may be repeated any number of times to form
a tape of wrapping material 864 having any length appropriate for
use on a bobbin or other structure configured to provide wrapping
material to a cigarette assembly machine. As will be recognized by
one of ordinary skill in the art, the positioning of the foil
strips along the wrapping material preferably will be precisely
controlled. Any variation in the positioning may lead to
misalignment between a foil strip and a substrate cavity. The tape
of wrapping material may be severed, for example, at approximately
the longitudinal center of the first segment 901 to form a piece of
wrapping material suitable for assembling a single two-up rod as
described above. Optical monitoring devices and/or other monitoring
devices may be included in or with an assembly machine and
incorporated into its operation to maintain accurate
alignment/registration of the foil segments with other smoking
article components (e.g., heat element segment, substrate segment)
during assembly of smoking articles.
[0081] FIG. 10 illustrates another example of the construction of a
smoking article using a two-up rod. A two-up aerosol generation
segment 1012 may be provided. The two-up aerosol generation segment
may include two aerosol generation segments joined to one another.
For example, the two-up aerosol generation segment 1012 may include
two heat generation segments 1035a, 1035b positioned at opposite
longitudinal ends thereof. A substrate segment 1055 may be
substantially centered between the heat generation segments 1035a,
1035b along the longitudinal axis of the two-up aerosol generation
segment 1012. The substrate segment 1055 may include two substrate
segments 1055a, 1055b each associated with one aerosol generation
segment. The heat generation segments 1035a, 1035b and the
substrate segments 1055a, 1055b may be joined to one another by a
circumscribing wrapping material 1058. The wrapping material 1058
may be constructed as described herein and elsewhere in this and
other embodiments configured to be practiced within the scope of
the present invention. For example, the wrapping material 1058 may
circumscribe at least a portion of the heat generation segment
1035a, the substrate segments 1055a, 1055b, and at least a portion
of the second heat generation segment 1035b. The wrapping material
1058 may include a foil strip laminated thereto as described above.
The foil strip may enhance heat transfer between the heat
generation segments and the substrate segments.
[0082] The components of the two-up aerosol generation segment 1012
may be constructed as described herein and elsewhere in this and
other embodiments configured to be practiced within the scope of
the present invention. For example, the substrate segment may
include any type of substrate including, for example, a monolithic
substrate or tobacco pellet substrate. The substrate segment may be
formed as a single segment of substrate material (e.g., a single
piece of extruded monolithic substrate material or a single segment
of tobacco pellet substrate material) or multiple segments of
substrate material (e.g., two or more pieces of extruded monolithic
substrate material or two or more segments of tobacco pellet
substrate material). The substrate may be disposed within a
cylindrical container structure. For example, the substrate segment
1055 may include two segments 1055a, 1055b each including a
substrate cavity or container at least partially filled with
tobacco pellet substrate material. The substrate cavity or
container may be defined by the wrapping material 1058.
Alternatively, a discrete substrate cavity or container may be
disposed within the wrapping material 1058.
[0083] The two-up aerosol generation segment 1012 may be severed at
about its longitudinal center to form two heat generation segments,
each generally configured as described above. The two heat
generation segments may be positioned at opposite ends of a tobacco
rod 1069, as shown in FIG. 10, to form a two-up rod 1013. The
two-up rod 1013 may be configured generally as described with
reference to FIG. 8. For example, the two-up rod 1013 may include
two intermediate segments joined to one another at a common tobacco
rod as described above. The tobacco rod 1069 may include two
portions 1069a, 1069b each associated with one intermediate
segment. The tobacco rod 1069 and the two aerosol generation
segments may be joined to one another with wrapping material 1064.
The wrapping material 1064 may circumscribe at least a portion of
each aerosol generation segment (e.g., at least a portion of the
substrate segments 1055a, 1055b and/or at least a portion of the
heat generation segments 1035a, 1035b) and the tobacco rod
1069.
[0084] The two-up rod may be severed at about its longitudinal
center to form two intermediate segments. The two intermediate
segments may be positioned at opposite ends of a filter segment
1065, as shown in FIG. 10, to form a two-up cigarette rod 1015. The
two-up cigarette rod may include two intermediate segments joined
to one another at a common filter segment 1065. The filter segment
1065 may include two portions 1065a, 1065b each associated with one
cigarette rod. The filter segment 1065 and the two intermediate
segments may be joined to one another with wrapping material 1078.
For example, wrapping material 1078 may circumscribe at least a
portion of each intermediate segment (e.g., a portion of each
tobacco rod 1069a, 1069b) and the filter segment 1065. The wrapping
material 1078 may be configured as a tipping material as described
above. The two-up cigarette rod may be severed at about its
longitudinal center (i.e., at about the longitudinal center of the
filter segment 1065) to form two smoking articles 1010a, 1010b. The
smoking articles may be constructed as described herein and
elsewhere in this and other embodiments configured to be practiced
within the scope of the present invention.
[0085] In another embodiment, a smoking article may be constructed
with a substrate 1163 including tobacco pellets, described here
with reference to FIG. 11, which is a partial perspective view of a
cigarette 1110 having a lighting end 1114 and a mouth end 1118. The
substrate 1163 (which may be used in other embodiments) may be
formed by any appropriate method, such as a marumarization method.
The cigarette body includes a tobacco rod 1169 disposed between the
substrate 1163 and the filter 1170. The heat-generation segment
1135 and other components may be constructed as described herein
and elsewhere in this and other embodiments configured to be
practiced within the scope of the present invention. For example,
the heat-generation segment 1135 may include one or more grooves
formed in an outer surface thereof. The grooves may extend
longitudinally along the outer surface of the heat-generation
segment 1135. In one preferred embodiment, the heat-generation
segment 1135 may include 8 grooves disposed around an outer
circumference thereof. The heat-generation segment also may include
one or more longitudinal channels formed therethrough. The grooves
and/or channels may provide a desired airflow through the
heat-generation segment 1135. To that end, any number of grooves
and/or channels may be included, and the grooves and/or channels
may have any desired shape or size. For example, the grooves and/or
channels may be configured as described in U.S. Pat. App. Publ. No.
2012/0042885 to Stone et al., which is incorporated by reference
herein in its entirety.
[0086] FIG. 12 illustrates another example of the construction of a
smoking article. A wrapping material 1264 may be formed into a tube
or column. The wrapping material 1264 may be constructed as
described herein and elsewhere in this and other embodiments
configured to be practiced within the scope of the present
invention. For example, the wrapping material 1264 may include a
paper material having one or more foil strips or patches laminated
to a surface thereof. The foil strips may be arranged to align with
various portions of the smoking article as further described
herein. A heat generation segment 1235 may be inserted into the
upstream end of the tube. The heat generation segment 1235 may be
advanced downstream within the tube until at least a portion of the
heat generation segment is received within and/or circumscribed by
the tube. The heat generation segment 1235 may be advanced
downstream within the tube until substantially the entire heat
generation segment is positioned within the tube. Alternatively, a
portion of the heat generation segment 1235 may protrude from the
upstream end of the tube as shown in FIG. 12.
[0087] A substrate material 1263 may be introduced into the
downstream end of the tube. The substrate material 1263 may be
advanced upstream within the tube to a position proximate the heat
generation segment 1235. The heat generation segment 1235 and the
substrate material 1263 may cooperatively form an
aerosol-generation system as described above. The substrate
material 1263 may be constructed as described herein and elsewhere
in this and other embodiments configured to be practiced within the
scope of the present invention. For example, the substrate material
may be configured as a tobacco pellet substrate material as
described above. A segment of the tube positioned adjacent the heat
generation segment 1035 may be at least partially filled with the
tobacco pellet substrate material. In other words, the tobacco
pellet substrate material may be dispensed into a segment of the
tube positioned downstream and adjacent the heat generation segment
1035 to at least partially fill the segment of the tube. In this
manner, the segment of the tube may be configured as a container or
capsule to receive the tobacco pellet substrate material 1263. The
tube may be placed in a vertical configuration during introduction
of the substrate material, with the heat generation segment 1235
positioned at the bottom end of the vertical tube. In this manner,
the heat generation segment 1235 may be used to plug the bottom end
of the tube. The substrate material may be introduced into the top
end of the vertical tube and allowed to fill a segment of the tube
above the heat generation segment 1235.
[0088] A tobacco rod 1269 may be introduced into the downstream end
of the tube. The tobacco rod may be advanced upstream within the
tube to be positioned proximate the substrate material 1263. In
this manner, a substrate cavity or compartment may be formed by the
heat generation segment 1235, the tube of wrapping material 1264,
and the tobacco rod 1269. The substrate cavity may be configured as
described above with reference to FIG. 7. With the substrate
material 1263 confined within the tube between the heat generation
segment 1235 and the tobacco rod 1269, further processing of the
components of the smoking article may be performed while retaining
the substrate material within the tube. In other words, the
substrate material may be substantially unable to migrate within or
out of the wrapping material tube during further processing
steps.
[0089] The heat generation segment 1235, the substrate material
1263, and/or the tobacco rod 1269 may be attached to one another
with the wrapping material tube. The tobacco rod 1269 may help to
retain the substrate material 1263 within the wrapping material
tube for further processing. In one example, a second tobacco rod,
a hollow filter, or both may be introduced into the downstream end
of the tube and advanced upstream within the tube to be positioned
proximate the tobacco rod 1269. The second tobacco rod may include
multiple (e.g., two or more) tobacco rods of the same or different
types of tobacco. The lengths of the tobacco rod 1269, a second
tobacco rod, and/or the hollow filter may affect (e.g., reduce) the
temperature and/or the sensory properties of the aerosol drawn
therethrough. In one example the tobacco rod 1269 may have a length
ranging from about 5 mm to about 20 mm. In one example, a second
tobacco rod, a hollow filter, or both may have a length ranging
from about 10 mm to about 40 mm. Thus, an intermediate segment,
which may be configured generally as described above with reference
to FIGS. 7-8, may be formed. A tobacco rod, a hollow tube, and/or a
filter element may be attached to the downstream end of the tube by
any means to form a smoking article as described above. The
wrapping material tube may circumscribe at least a portion of the
heat generation segment, the substrate material, and at least a
portion of the tobacco rod. A foil strip, which may be laminated to
a surface of the wrapping material, may circumscribe the substrate
material as described above.
[0090] In other embodiments, a tobacco pellet substrate or an
extruded or other monolithic substrate may be used in place of the
substrates discussed herein with reference, for example, to FIGS. 1
and 2. For example, in one embodiment, the substrate 55 of FIG. 1
may be replaced with a tobacco pellet substrate disposed within a
substrate cavity or a monolithic substrate having one or more
internal longitudinal channels and/or one or more external grooves.
Various other filter designs may be used including perforated
filters made of non-cellular acetate materials known in the art, as
well as other filter configurations now known or forthcoming, all
within the scope of the present invention. The other portions of
cigarettes made with tobacco pellet substrates or extruded or other
monolithic substrates may also be modified in accordance with the
state of the art, and still be practiced within the scope of the
present invention.
Examples 1-4
Composite Tobacco Pellet Samples
[0091] In one example, four composite tobacco pellet substrates
were formed according to processes described herein, and they
included the following components:
TABLE-US-00001 Weight- Weight- Weight- Weight- Percent Percent
Percent Percent Component (Example 1) (Example 2) (Example 3)
(Example 4) Tobacco Blend 40 30 20 35 (powder) Glycerol 20 20 20 30
CaCo.sub.3 40 50 60 35
[0092] The tobacco blend powder was a blend of 50% flue-cured
tobacco, 30% burley tobacco, and 20% oriental tobacco. The tobacco
was ground to a particle size of about 10 microns. The calcium
carbonate was precipitated agglomerated calcium carbonate.
Examples 5-8
Flavored Composite Tobacco Pellet Samples
[0093] In another example, four flavored composite tobacco pellet
substrates were formed according to processes described herein, and
they included the following components:
TABLE-US-00002 Weight- Weight- Weight- Weight- Percent Percent
Percent Percent Component (Example 5) (Example 6) (Example 7)
(Example 8) Tobacco Blend 30 29.7 25 25 (powder) Glycerol 20 0 20
20 CaCo.sub.3 50 49.7 50 50 Coffee (finely 0 0 5 5 ground or
instant at 50:50 w/w) Vanillin 0 20.6 0 0 (~0.6%) in B3
The tobacco blend powder was a blend of 50% flue-cured tobacco, 30%
burley tobacco, and 20% oriental tobacco. The tobacco was ground to
a particle size of about 10 microns. The calcium carbonate was
precipitated agglomerated calcium carbonate.
[0094] A binder may be added to any of the examples described above
(e.g., Examples 1-8, or any other examples). The binder may
include, for example, CMC, a gum (e.g., guar gum), xanthan,
pullulan, or an alginate. The binder may be added by a total weight
basis, preferably ranging from about 0 to about 15% of the final
mixture.
[0095] Cigarettes of the present invention may be air-diluted or
ventilated such that the amount of air dilution for an air diluted
cigarette may be about 10 percent to about 80 percent. As used
herein, the term "air dilution" is the ratio (expressed as a
percentage) of the volume of air drawn through the air dilution
means to the total volume of air and aerosol drawn through the
cigarette and exiting the mouth end portion of the cigarette.
Higher air dilution levels can act to reduce the transfer
efficiency of aerosol-forming material into mainstream aerosol.
[0096] Preferred embodiments of cigarettes of the present
invention, when smoked, yield an acceptable number of puffs. Such
cigarettes normally provide more than about 6 puffs, and generally
more than about 8 puffs, per cigarette, when machine-smoked under
standardized smoking conditions. Such cigarettes normally provide
less than about 15 puffs, and generally less than about 12 puffs,
per cigarette, when smoked under standardized smoking conditions.
Standardized smoking conditions consist of 35 ml puffs of 2 second
duration separated by 58 seconds of smolder.
[0097] Aerosols that are produced by cigarettes of the present
invention are those that comprise air-containing components such as
vapors, gases, suspended particulates, and the like. Aerosol
components can be generated from burning tobacco of some form (and
optionally other components that are burned to generate heat); by
thermally decomposing tobacco caused by heating tobacco and
charring tobacco (or otherwise causing tobacco to undergo some form
of smolder); and by vaporizing aerosol-forming agent. As such, the
aerosol can contain volatilized components, combustion products
(e.g., carbon dioxide and water), incomplete combustion products,
and products of pyrolysis.
[0098] Aerosol components may also be generated by the action of
heat from burning tobacco of some form (and optionally other
components that are burned to generate heat), upon substances that
are located in a heat exchange relationship with tobacco material
that is burned and other components that are burned. Aerosol
components may also be generated by the aerosol-generation system
as a result of the action of the heat generation segment upon an
aerosol-generating segment. In some embodiments, components of the
aerosol-generating segment have an overall composition, and are
positioned within the smoking article, such that those components
will have a tendency not to undergo a significant degree of thermal
decomposition (e.g., as a result of combustion, smoldering or
pyrolysis) during conditions of normal use.
[0099] Drawings in the figures illustrating various embodiments are
not necessarily to scale. Some drawings may have certain details
magnified for emphasis, and any different numbers or proportions of
parts should not be read as limiting, unless so-designated by one
or more claims. Those of skill in the art will appreciate that
embodiments not expressly illustrated herein may be practiced
within the scope of the present invention, including that features
described herein for different embodiments may be combined with
each other and/or with currently-known or future-developed
technologies while remaining within the scope of the claims
presented here. It is therefore intended that the foregoing
detailed description be regarded as illustrative rather than
limiting. And, it should be understood that the following claims,
including all equivalents, are intended to define the spirit and
scope of this invention.
* * * * *